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SpaceX says upgraded Starlink satellites have better bandwidth, beams, and more

During the Starlink-1 launch webcast, SpaceX described some of the significant upgrades it has made to its Starlink satellites, ranging from massively improved bandwidth to "100% demisability". (SpaceX - edit by Teslarati)

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Just hours ago, SpaceX successfully launched its second batch of 60 Starlink satellites, featuring a variety of upgrades as part of the move from v0.9 to v1.0 spacecraft. During SpaceX’s launch webcast, the hosts revealed a number of intriguing new details about those upgrades, shedding a bit more light on what exactly has changed.

SpaceX launched its first dedicated Starlink mission in May 2019, placing 60 “v0.9” satellites in low Earth orbit (LEO) in what was essentially a beta test at an unprecedented scale. At the time, SpaceX and CEO Elon Musk disseminated a substantial amount of information, essentially taking the veil off of (part of) the company’s Starlink satellite program. In terms of the basics, Starlink v0.9 satellites were said to weigh approximately ~225 kg (500 lb) apiece, although the final mass – said to be the heaviest payload SpaceX had ever launched – suggested that that figure excluded the mass of krypton propellant.

All told, Musk said that the payload weighed ~18.5 tons but never clarified whether that was in imperial or metric units, leaving a potential range of 16,700-18,500 kilograms (36,800-40,800 pounds). In general, Musk was quite confident that SpaceX’s custom-built phased array antennas were effectively the best in the world even in their v0.9 beta-test iteration. Additionally, he noted that inter-satellite optical (i.e. laser) links would have to wait a generation or two before becoming part of the operational constellation.

Ch-ch-ch-changes

With SpaceX’s Starlink-1 launch, the second 60-satellite mission, the company debuted Starlink ‘v1.0’ satellites with a range of changes and upgrades that fall under two main categories: structures and communications.

Prior to the November 11th webcast, SpaceX’s official pre-launch press kit was far less revealing than Starlink v0.9’s but did note that v1.0 satellites have been upgraded to be “100% demisable”. This means that when each spacecraft reenters Earth’s atmosphere, everything down to the last shred of mylar is now expected to burn up before reaching the ground, reducing the (already miniscule) risk of debris harming people or property. Similarly, SpaceX implied several months before launch that v1.0 spacecraft would include tweaks to limit their reflectiveness after the astronomy community stoked fears about potential impacts.

A stack of 60 Starlink v0.9 satellites are prepared for their orbital launch debut in May 2019. (SpaceX)
60 v0.9 Starlink satellites ahead of their May 2019 debut. (SpaceX)
60 Starlink v1.0 satellites prepare for flight. A move to matte finishes is one immediately visible albedo-related change present on the new design. (SpaceX)

Aside from a general improvement to the overall visual fit-and-finish of the v1.0 spacecraft, SpaceX’s official comments on the matter indicated that the most substantial changes between v0.9 and v1.0 were more related to each spacecraft’s advanced electronics and payloads. In the case of Starlink, each satellite’s primary payload is a high-performance suite of electronically-steered phased array antennas. Initially developed to improve the flexibility of tracking and scanning radars used by military fighter aircraft, phased array antennas (and radar) allow multiple beams to be aimed without physically moving the antenna.

SpaceX says that Starlink v1.0 satellites added a number of Ka-band antennas alongside upgraded Ku-band hardware similar to what was installed on Starlink v0.9. Ka and Ku refer to similar but different communications frequencies, with Ku-band generally offering greater reliability and cloud/rain tolerance, while Ka-band is a bit more sensitive to environmental factors but offers a substantially higher theoretical bandwidth.

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60 Starlink v1.0 satellites deploy in one giant, ~18-metric-ton blob. What look like white cutouts are each spacecraft’s large solar array seen prior to deployment. (SpaceX)
On the right, Starlink’s phased array antennas are visible as four shiny panels on the matte aluminum rear of the satellite bus. (SpaceX)

According to SpaceX engineers speaking during the Starlink-1 launch webcast, Starlink v1.0 satellites offer an unexpected 400% increase in overall bandwidth, meaning they can theoretically transmit four times as much data per any given second. Additionally, Starlink v1.0 satellites were said to feature antennas with twice as many steerable beams, meaning that they can effectively serve two times as many regions simultaneously. It’s unclear if the addition of Ka-band antennas is the sole source of these substantial improvements.

Furthermore, during the Starlink v0.9 launch, SpaceX CEO Elon Musk indicated that the 60 satellites represented a bandwidth of more than 1 terabit per second (Tbps), translating to ~17 Gbps per satellite. More likely than not, Musk was speaking aspirational and the v0.9 satellites actually represented more like ~200-300 Gbps worth of throughput, with the additional of Ka-band antennas and perhaps general technology upgrades bringing v1.0 satellites to a nominal ~17 Gbps apiece.

For now, 60 Starlink v1.0 satellites are now in orbit and are rapidly spreading out after their bizarre but effective blob-style deployment. With any luck, all 60 will successfully deploy their solar arrays and begin propelling themselves towards their final operating orbits with krypton-fueled ion thrusters. Stay tuned for updates from SpaceX!

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Eric Ralph is Teslarati's senior spaceflight reporter and has been covering the industry in some capacity for almost half a decade, largely spurred in 2016 by a trip to Mexico to watch Elon Musk reveal SpaceX's plans for Mars in person. Aside from spreading interest and excitement about spaceflight far and wide, his primary goal is to cover humanity's ongoing efforts to expand beyond Earth to the Moon, Mars, and elsewhere.

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New drone video shows Tesla’s Optimus Factory reaching a turning point

New drone footage shows Tesla’s dedicated Optimus factory steel frame nearing completion at Giga Texas.

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Tesla’s dedicated Optimus factory at Gigafactory Texas is closing in on a finished steel frame, according to drone footage posted Thursday afternoon by longtime site observer Joe Tegtmeyer. In the video, Tegtmeyer said structural steel assembly is now about five column grids away from reaching the building’s north perimeter beam, putting the primary skeleton in its final stretch roughly six months after Tesla broke ground on the North Campus site in late March.

Tegtmeyer’s footage shows concrete already going in on three upper floors while crews continue laying rebar and pouring grade beam footings at ground level. That kind of parallel work, steel rising at one end of the site while concrete sets at the other, is a scheduling approach Tesla used at the original Giga Texas building and appears to be repeating here to save time before the plant’s targeted 2027 production start.

Teslarati has tracked the building’s progress since Tesla confirmed construction was officially underway in May, when the first steel structure went up on what was then bare, reclaimed land. The facility is part of a more than 5.2 million square foot expansion of Giga Texas’s North Campus that Tesla has said will eventually run nearly the length of the existing vehicle factory, over 4,000 feet, while sitting somewhat narrower. Musk has pegged the long term output target at 10 million Optimus units a year once the line is running at full capacity, a volume that would dwarf the one million unit pilot line Tesla is standing up separately at its Fremont, California factory.

Tesla Giga Texas to feature massive Optimus V4 production line

The Texas facility sits alongside another major buildout on the same campus. Terafab, the joint Tesla and SpaceX chip fabrication plant that will eventually supply the silicon running Optimus units in the field. Housing robot assembly and chip production on the same grounds is a deliberate supply chain decision, cutting down on the shipping and lead time that would otherwise sit between the two.

Tesla has not given an updated timeline beyond its previously stated goal of bringing high volume Optimus production online at the site in the summer of 2027. Fremont’s smaller pilot line began mass producing the current Gen 3 robot in January, with that plant expected to build tens of thousands of units this year primarily to generate the real world data Tesla needs to refine the robot’s software before Giga Texas ramps up. Six months of visible construction progress, tracked almost entirely through Tegtmeyer’s recurring drone flights, gives the clearest outside look yet at how seriously Tesla is treating that 2027 deadline.

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Tesla and SpaceX take “Terafab” Trademark fight to Federal Court

Tesla and SpaceX sue a small Illinois firm after cease and desist letters over Terafab.

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SpaceX Terafab rendering

Tesla and SpaceX are asking a federal judge to rule that their planned Terafab chip factory does not infringe a small Illinois company’s trademark, a request that arrives only after months of quiet negotiation broke down this summer.

The dispute traces to May 18, when Tesla filed three U.S. trademark applications for “Terafab” and “Tesla Terafab,” covering semiconductor chips and related chip making services. TERA-print LLC, a nanotechnology company that has held a federal trademark for “Tera-Fab” since 2021, responded five days later with a cease and desist letter. According to the lawsuit, first reported by Reuters, TERA-print argued that Tesla and SpaceX’s use of “Terafab” would confuse consumers familiar with its own trademark, which covers a desktop photolithography printer sold to researchers for sensor and bioengineering work.

What stands out in the filing is the timing of TERA-print’s own paperwork. One day before sending that cease and desist letter, on May 22, TERA-print applied to expand its existing registration to cover semiconductor materials, silicon chips, nanoelectronic devices and AI design services, categories it had not previously claimed. Tesla and SpaceX call that filing opportunistic in their complaint, noting it arrived two months after Tesla’s public Terafab announcement and just days after Tesla’s own trademark applications went in.

Elon Musk launches TERAFAB: The $25B Tesla-SpaceXAI chip factory that will rewire the AI industry

By June 10, TERA-print was threatening to sue for federal trademark infringement, false designation of origin and unfair competition, the complaint states. Rather than wait to be sued, Tesla, SpaceX and SpaceXAI met with TERA-print six separate times between June and August trying to resolve the dispute directly. Those talks collapsed, and the companies filed for declaratory judgment this week in the U.S. District Court for the Western District of Texas, asking a judge to find that “Terafab” does not infringe TERA-print’s mark before TERA-print can file a claim of its own.

TERA-print isn’t backing down. The company told PCMag it discussed a settlement with Tesla as recently as September 2 and feels misled by what it called Tesla’s professed interest in settling. Its CTO, Andrey Ivankin, said TERA-print holds a Defense Department contract to fabricate semiconductors and partially owns Mattiq Inc., an AI company built on TERA-print’s products, and that the company will vigorously defend its rights.

Tesla and SpaceX argue the overlap is superficial. Terafab is planned as a $16.8 billion complex spanning roughly 100 million square feet at the Grimes County site SpaceX confirmed last month, built to produce chips for Optimus robots, Tesla’s AI computing needs and SpaceX’s orbital data center ambitions, a scale and purpose the companies say no reasonable consumer would confuse with a tabletop lab printer. TERA-print’s product line has stayed focused on lithography tools for biological and sensor research since it registered its mark in 2021.

The trademark fight is the second legal dispute tied to the Terafab project in the past week, following a separate SpaceX suit aimed at keeping company records about the facility out of public view, as KBTX reported. Whether construction proceeds under the Terafab name now depends on a federal judge in Austin.

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NHTSA just escalated its Tesla Cybercab investigation in a big way

NHTSA escalated its Cybercab audit into a sworn Special Order with a September 30 deadline.

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Federal regulators have moved from asking Tesla questions about its Cybercab to demanding sworn answers. The National Highway Traffic Safety Administration issued a Special Order that requires a Tesla officer to sign an affidavit attesting to the completeness of the company’s responses, with a deadline of September 30.

The order builds on Audit Query AQ26002, which NHTSA opened on September 3, the same day Tesla began commercial Cybercab service in Austin. Teslarati covered that initial inquiry when it surfaced, noting the agency wanted to understand how Tesla certified a vehicle with no permanently attached steering wheel, pedals, or mirrors as compliant with Federal Motor Vehicle Safety Standards. A Special Order is a different tool and converts a fact finding review into a legally enforceable demand, the same mechanism NHTSA used against Tesla in 2023 during its Autopilot investigation.

Several of the 21 requests target a specific gap in Cybercab’s design. One asks whether Tesla used temporarily attached human controls at any point to help certify the vehicle, and if so, which standards depended on that equipment being present. Another quotes an existing rule directly: “The service brakes shall be activated by means of a foot control.” Cybercab has no foot pedal. NHTSA wants a detailed explanation of how the vehicle satisfies that requirement, and how it complies without the kind of exemption granted to Zoox in July under Part 555, the regulatory pathway built for steering wheel free vehicles.

The order does not claim Cybercab is unsafe or that Tesla broke a rule. It requires Tesla to explain, under oath, the reasoning behind decisions the company already made when it self-certified the vehicle. That distinction matters, but so does the exposure. Motor1’s reporting, summarized here, put potential civil penalty exposure as high as $139 million if NHTSA later finds the certification was flawed, on top of whatever criminal risk comes with a false sworn statement.

Tesla has not said publicly how it plans to respond. Cybercab is still carrying passengers in Austin through the Robotaxi app while the September 30 deadline approaches, and the company has continued expanding the vehicle’s footprint even as the regulatory question remains open. The Special Order does not pause any of that and just sets a date by which Tesla has to put its certification logic on the record, with a company officer’s name attached to it.

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